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Robur Caldaia 100.2 Tech Installation, Use And Maintenance Manual

Outdoor condensing boiler for heating medium and large buildings
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Installation, use and maintenance manual
Caldaia 55.1 and 100.2 Tech
Outdoor condensing boiler
for heating medium and large buildings
Powered by natural gas/LPG

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Summary of Contents for Robur Caldaia 100.2 Tech

  • Page 1 Installation, use and maintenance manual Caldaia 55.1 and 100.2 Tech Outdoor condensing boiler for heating medium and large buildings Powered by natural gas/LPG...
  • Page 2 The rights of those who have legitimately filed the registered trademarks contained within this publication are not affected. With the aim of continuously improving the quality of its products, Robur S.p.A. reserves the right to modify the data and contents of this Installation, use and maintenance manual without prior notice.

  • Page 3: Table Of Contents

    INDEX OF CONTENTS Introduction Control device ..............p. 24 ................p. 4 Control through optional OCDS006 remote Recipients ................p. 4 control - recommended solution ......p. 25 II Symbols and definitions ..........p. 4 Positioning the control system ........ p. 25 II.1 Key to symbols ..............p. 4 Operation via centralised external request ..

  • Page 4: Iintroduction

    Boiler/External module = equivalent terms, both used to des- ignate the part of the appliance to be installed outside the room DANGER to be heated. TAC = Technical Assistance Centre authorised by Robur. Remote control = optional control device with chronothermo- WARNING stat function.

  • Page 5: Iii.2 Conformity

    Warnings Limescale and corrosion „ Do not entrust children, persons with physical, sensory or mental disabilities or persons with poor knowledge Depending on the chemical/physical properties of the and experience with use of the appliance. system water, limescale or corrosion may damage the appliance.

  • Page 6: Iii.3

    Warnings III.3 EXCLUSIONS OF LIABILITY AND added. 2014/30/EC "Electromagnetic Compatibility Directive" as WARRANTY ▶ amended and added. 2014/35/EC "Low Voltage Directive" as amended and added. ▶ Any contractual or extra-contractual liability of the man- 2006/42/EC "Machine Directive" as amended and added. ▶...

  • Page 7: Features And Technical Data

    The limit thermostat has manual reset. Figure 1.1   Caldaia 55.1 dimensions Mechanical and thermo-hydraulic components Integrated spiral single tube stainless steel heat exchanger ▶ (2 heat exchangers for Caldaia 100.2 Tech). Premix modulating burner with 1:9 ratio. ▶ Automatic air vent valve. ▶...
  • Page 8 Features and technical data Figure 1.2   Caldaia 55.1 hydraulic connections (bottom panel view) Figure 1.4   Caldaia 100.2 hydraulic connections (bottom panel view) 89,5 Delivery Ø 1 1/2" M Return Ø 1 1/2" M Gas Ø 1" M Delivery Ø 1 1/4" M Condensate drain Return Ø...

  • Page 9: Components

    Features and technical data COMPONENTS Figure 1.5   Caldaia 55.1 internal components Flue safety thermal fuse Ignition electrode INAIL approved maximum pressure lock switch Heat exchanger Air intake pipe INAIL approved minimum pressure lock switch Burner unit Ignition transformer Pressure gauge connection tap with test flange Flame detector Venturi and shock absorber pipe...
  • Page 10 Features and technical data Figure 1.6   55.1 boiler hydraulic diagram Flue safety thermal fuse Air intake pipe INAIL-compliant pressure gauge Heat exchanger Ignition transformer System delivery connection Burner unit Venturi System return connection Flame detector Safety valve INAIL approved safety valve Heating return probe Water pressure switch Expansion tank...
  • Page 11 Features and technical data Figure 1.7   Caldaia 100.2 internal components Installation, use and maintenance manual – Caldaia 55.1 and 100.2 Tech...
  • Page 12 Features and technical data Figure 1.8   100.2 boiler hydraulic diagram Flue safety thermal fuse Condensate drain hose Pressure gauge connection tap with test Slave unit heat exchanger Water pressure switch flange and shock absorber pipe Burner unit Manifold probe INAIL-compliant pressure gauge Flame detector Master unit heat exchanger In-line shut-off valve...

  • Page 13: Technical Characteristics

    Features and technical data TECHNICAL CHARACTERISTICS Table 1.1   Technical data of external modules Caldaia 55.1 Tech Caldaia 100.2 Tech Heating mode seasonal space heating energy efficiency class (ErP) nominal (1013 mbar - 15 °C) (1) 50,0 99,8 Heat input minimum (1)
  • Page 14 4270/ 15 PWM1 50,0 3780/ 25 PWM1 40,0 PWM1 3280/ 35 PWM1 30,0 2780/ 45 2280/ 55 PWM1 20,0 PWM1 1780/65 1290/ 75 PWM1 10,0 Q/m³/h Q/l/s Q/Igpm [m3/h] max. P1/W Q/m³/h In Caldaia 100.2 Tech there are 2 circulators.

  • Page 15: Electrical Wiring Diagram

    Features and technical data ELECTRICAL WIRING DIAGRAM Figure 1.11   55.1 boiler electrical connections diagram t> gi/ne p> p< Pacq INAIL 220 V 50 Hz Flame detector Standby contact Line Ignition electrode Connector for optional outdoor tempera- Neutral Modulating circulator ture probe Black Gas valve Connector for optional room thermostat...
  • Page 16 Features and technical data Figure 1.12   100.2 boiler electrical connections diagram - slave board GND +24V TXOUT RXIN Flame detector temperature probe Air pressure switch Ignition electrode Connector for optional room thermostat Flue gas thermofuse Modulating circulator Line Heating return probe Gas valve Neutral Light blue...
  • Page 17 Features and technical data Figure 1.13   100.2 boiler electrical connections diagram - master board INAIL p < p > t > GND +24V TXOUT RXIN Pacq Flame detector Heating delivery probe Black Ignition electrode Blower Light blue Modulating circulator Flue gas thermofuse Brown Standby contact Heating return probe...

  • Page 18: Transport And Positioning

    Transport and positioning TRANSPORT AND POSITIONING WARNINGS MINIMUM CLEARANCE DISTANCES Damage from transport or installation Keep the appliance away from combustible or flam- mable materials or components, in compliance with ap- plicable regulations. The manufacturer shall not be liable for any damage dur- ing appliance transport and installation.

  • Page 19: Hydraulic Connections

    „ Caldaia 55.1 Tech: nominal flow at the maximum availa- 9. Mount the fitting cover. ble head = 2150 l/h „ Caldaia 100.2 Tech: nominal flow at the maximum avail- Figure 3.1   Boiler installation able head = 4300 l/h „ Residual pressure head at nominal flow rate = 2,5 m w.c.
  • Page 20 Heating engineer For the calculation of the total water content to be 3.3.2.1 System water characteristics loaded in the system it is necessary to add the water content of the boiler (Table 1.1  p. 13 ) and of the distri- Responsibility of the user/operator/installer bution terminals to the water content in the pipes.

  • Page 21: Combustion Products Exhaust

    3.4.1 Flue gas exhaust connection Caldaia 55.1 Tech: Ø 80 mm ▶ Caldaia 100.2 Tech: Ø 100 mm ▶ on the upper side of the boiler (Figure 1.1  p.  7 and Figure 1.4  p. 8 ). The Caldaia 55.1 Tech is supplied with a flanged socket (60/80 mm), complete with a socket for flue gas analysis (detail PF in Figure 5.8 ...

  • Page 22: Pump Antifreeze And Anti-Lock Function

    Ø 80 mm, length 1000 mm elbow 90° Ø 80 mm 17,5 elbow 45° Ø 80 mm Caldaia 100.2 Tech extension pipe Ø 100 mm, length 1000 mm elbow 90° Ø 100 mm elbow 45° Ø 100 mm...
  • Page 23 Heating engineer Gas pipes sizing pressure of 50 mbar. The gas pipes must not cause excessive pressure drops and, con- The appliance's gas supply pressure, both static and dynamic, sequently, insufficient gas pressure for the appliance. must comply with Table 3.4  p. 23 , with tolerance ± 15%. Supply gas pressure Non compliant gas pressure (Table 3.4 ...

  • Page 24: Electrical Installer

    Electrical installer If it is necessary to change the type of gas supply to Vertical pipes and condensate the boiler, contact the TAC that will make the necessary Vertical gas pipes must be fitted with siphon and discharge ▶ changes. of the condensate that may form inside the pipe.

  • Page 25: Control Through Optional Ocds006 Remote Control - Recommended Solution

    For the electrical connection of the remote control, follow the For further information on the operation and use of instructions given in Paragraph 4.3  p. 24 . boilers in this mode, please contact the Robur technical service. The remote control is electrically connected to the boiler by means of two non-polarized conductors through Figure 4.2  ...

  • Page 26: Preliminary Checks

    All situations that may involve operation abnormalities or ▶ are potentially hazardous. 5.2.1 Caldaia 100.2 Tech 5.1.3 Non-compliant system and corrective actions To work on the front side of the boiler (Figure 5.2  p. 27 ): Should the TAC find any non conformities, the user/installer is 1.

  • Page 27: How To Access The Control Panel

    First start-up Figure 5.2   Accessing the Caldaia 100.2 boiler Figure 5.3   Accessing the control panel Front panel fastening screws Front panel Cover fixing screws Slave control panel Cover fixing screws Cover Hooks (only on slave panel) Cover Fitting cover fastening screws Fitting cover Master control panel Lateral panel fastening screws Side panel...
  • Page 28 Slave control panel The operating parameters are shown in Table 5.1  p.  28 (Cal- daia 55.1 Tech) and 5.2  p.  29 (Caldaia 100.2 Tech) and are visi- ble on the internal display of the boiler Figure 5.5   Access and setting of boiler parameters Table 5.1  ...
  • Page 29 First start-up 0 = disabled Heating run-up 1 = 50 s It is possible to set the time, during the start-up phase, that the boiler takes to 0 - 4 2 = 100 s reach the maximum set power (for the space heating service). 3 = 200 s 4 = 400 s Heating timing...
  • Page 30 First start-up Gas type selection 0 = G20, G25, G25.3 WARNING: before changing the parameter value, read the instructions in Para- 0 - 1 1 = LPG, G30, G31 graph 5.6  p. 33 . 0 = standard (30-80 °C) Heating temperature setting 0 - 1 1 = reduced (25-45 °C) 0 = disabled...
  • Page 31 First start-up Figure 5.6   Climatic curves Tm (°C) Kd = 25 Kd = 30 Kd = 20 45 MAX Kd = 15 Kd = 10 Kd = 5 Kd = 0 25 MIN Te (°C) Tm Delivery temperature Outdoor temperature Heating control value Figure 5.7  ...

  • Page 32: Combustion Parameters Check

    First start-up Table 5.3   Gas type - Blower frequencies in heating mode Figure 5.8   Socket for flue gas analysis and gas valve Minimum blower Maximum blower Boiler Gas type frequency in heating frequency in heating mode (Hz) mode (Hz) Caldaia 55.1 G25.3 Tech Caldaia 100.2 G25.3...

  • Page 33: Gas Changeover

    First start-up GAS CHANGEOVER Figure 5.9   Gas changeover Paragraph reserved exclusively to TACs. The following instructions apply to both the conversion from natural gas (G20) to any other gas and vice versa. Check that the gas supply line is suitable for the new fuel type used to supply the unit.

  • Page 34: Switching Off

    NORMAL OPERATION This section is for the end user. after the Robur authorised TAC has completed the first start-up. The use of the device by the end user is only permitted Figure 6.1   External module control panel...

  • Page 35: Warnings

    (Figure 6.2  p. 35 ), while error E04 appears on First start-up may exclusively be carried out by a Robur the remote control (if any). When the correct pressure is TAC (Chapter 5  p. 25 ).

  • Page 36: Remote Control Operation (Optional)

    Maintenance REMOTE CONTROL OPERATION After a long period of unit inactivity or at the first start-up, it may be necessary to repeat the ignition operation a (OPTIONAL) few times due to the presence of air in the gas piping. For switching on, adjusting and switching off the boiler, 3.

  • Page 37: Diagnostics

    ▶ Open the drain tap (Figure 7.1  p.  37 for Caldaia 55.1 Tech ▶ and Figure 7.2  p. 37 for Caldaia 100.2 Tech). When all the water has drained off, close the drain tap. ▶ Figure 7.1   Caldaia 55.1 - Drain tap position...
  • Page 38 Automatic voltage Volts) returns to the required limits) In the Caldaia 100.2 Tech press the key on the master control panel. Only for boilers with DHW production. Only for Caldaia 100.2 Tech. Not applicable to Caldaia 100.2 Tech.
  • Page 39 Diagnostics Code Function Description Heating antifreeze It is automatically activated when the heating probe detects a temperature of 12 °C. The boiler operates at minimum power and is function deactivated when a temperature of 30 °C is detected. DHW antifreeze It is automatically activated when the DHW probe detects a temperature of 4 °C.

  • Page 40: Appendices

    Appendices APPENDICES PRODUCT FICHE Figure 9.1 Table 7 COMMISSION DELEGATED REGULATION (EU) No 811/2013 Technical parameters for boiler space heaters, boiler combination heaters and cogeneration space heaters Model(s): Caldaria 55.1 Condensing boiler: Low-temperature (**) boiler: B11 boiler: Cogeneration space heater: If yes, equipped with a supplementary heater: Combination heater: Item Symbol...
  • Page 41 Appendices Figure 9.2 Table 7 COMMISSION DELEGATED REGULATION (EU) No 811/2013 Technical parameters for boiler space heaters, boiler combination heaters and cogeneration space heaters Model(s): Caldaria 100.2 Condensing boiler: Low-temperature (**) boiler: B11 boiler: Cogeneration space heater: If yes, equipped with a supplementary heater: Combination heater: Item Symbol...
  • Page 44 Robur mission Robur is dedicated to dynamic progression in research, development and promotion of safe, environmentally-friendly, energy-efficiency products, through the commitment and caring of its employees and partners. Robur S.p.A. advanced technologies for climate conditioning via Parigi 4/6 24040 Verdellino/Zingonia (BG) Italy +39 035 888111 - F +39 035 884165 www.robur.it robur@robur.it...

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Caldaia 55.1 tech

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